Process of forming alpha corrugated board and product produced thereby



Apk-ia 27,192@

A.. CUMFEH PROCESS OF FORMING A CORRUGATED BOARD AND PRODUCT PRODUCED THEREBY Filed March 22, 3 Sheets-Shea?. 1

Apm 27,1926. v

- H. 3A. CUMFER PROCESS OF FORMING A GORRUGATED BOARD AND PRODUCT PRODUCED THEREBY 5 Sheets-Sheet 2 DVD.

April 2? 192%,

H. A. CUM'FEP;

PROCESS OF FORMINC A CCRRUCATED BOARD AND PRODUCT PRODUCED THEREBY 5' Sheets-Sheet 5 CHICAG, ILLIHIS, ASSGNGP," OF SNE-HALF T0 .ALBERT D.

@El .'TNSGEL KANSAS.

PEGEQ F ."EOltltlll'@ A COBR'UGATED BOARD .AND PRODUCT PRQDUCED THREBY.

Tall 'wfwm 'it mag/"concern:

, Be 1t known that i, Elsner A. Comun, a citizen of the United States, residing in the city or 'Chicago county of Cook9 und State or illinois., .have invented certain new und useful Improvements in Processes of Forining r. Corrugated Board and `Broduct Produced Thereby, of which the following is a specification.

This invention relates to improvements in a corrugated hoard, and relates more partie uiurly to a process in which. separate sheets are reid continuousy to a. machine, one or" which. is ccrrue'ated as it passes therethrough, is .hxedly united or annexed to the lower hose sheet to form o. relatively rigid end unitary structure.

This invention is in part a continuation of previous applications Serial Numbers 504,289 filed September 30th, 15921, .which has matured into Patents 1,525,071 und 582,n

tiled August ."LZth i922.

Among the salient objects of the invention are to provide o. corrugated sheet and Cai) 'lil

process of making saine, whereby separate sheets are combined or iedly united to each othera one of said sheets comprising s buse portion, and the other a corrugated 'element iiziedly ainalgainated to the hose, seid sheets being produced contiiiuouslg end severed to any predetermined desired sizes; to provide a corrugated structure in which per-- iol-ations or depressions of any desired conliguration may he made in the corrugated portions to facilitate the fixing or a plastic substance to the face of the sheet when utiiizing the corrugated sheet as luth elements; to provide a structure `which may he used for innumerable purposes such as hoxhoard, partitions for packing cases, bottle cases, and innumerable other uses; to provide a structure which is relatively cheap to construct, und one which is readily applicable to innuu'ieruhie industrial uses, and purposes.

Fig. l is a sideelevutionul view of the :1ppnratus. Fig. 2 is a plan view of the nzachine shown in l. Fig 3 is an enlarged detail of the corrugating mechanism and sheet combining portion oi the machine. Fig. 4lis a modified method of forming per- `l'orations in the corrugated portions of the sheet. Fig. 5 isan enlarged detail vieu showing the slitting of the corrugated portions in the preferred method of producing the sheet. Fig. 6 is i view of a portion of Applcstien lled March 22, M3553.

Y gating belt Serial No. 26,759. the sheet formed by the preferred method, and lli. Z is o. perspective of a portion of the sheet formed by the modified method of perforation. Fig. 8 is an enlarged detail view of the cutting knives used in the pre ferred niethod. Fig. 9 is a sectional, vieu7 taken along the line 9-9 in Fig. 6, and Fig. 10 is a view token along the line l0-10 in Fig-7.

Referring to the drawings, and briefly errplaining 'the method of producing theprod uct, separete sheets l and 2 are fed from rolls mounted ou reelsshewn disgronirnati cally ut 3 and Il respectively. The tvfo sheets are fed into the machine, the lower sheet `being passed through en adhesive cout ingr bath shown at 5 While the upper sheet is corrugated in o .manner shown in Fig. 3, and cut, as shown.

The lower end upper sheets ure then united and pressed together to form e uni tory structure which is passed on to a puriclo ing mechanism which presses the slit 'oortions into depressions shown in Fig. G, these depressed portions adhering to the lower adhesive coated sheet. The sheety is then passed on and cut .any desired lengths.

lescrihing now more in detail the method employed for niohing the corrugated pleister hoard, which has s. waterproof 'bese relotively stiff stool; known as chip-hoord, and having applied thereto a corrugated sheet which is perforated along the top of the raised corrugotions es shown in Fig. G in order that a lcstic substance such os plaster will adhere thereto, the portions of the plus tic covering being :forced in behind the edges of the apertures to pro-duce the keying etiect, and musing the ploeterto more tiredly ad here to the plaster hoord.

The details ci this construction ere brought out most ciearly in 5 and i?.

Referring to the drawings the upr sheet 2 passes from the rcel under the guide roll 6 und between the lower corrugating roll 7 and upper corruguting roll. 8 upon the periphery ot' which is corrieri a corro which comprises cross bers 9 united hy chain'linlrs 10. These cross hars register with the teeth of the lower corrufrating roll 7 While the sheet 2 is fed thereietv/een and receives a corrugated zigzag deformation. After passing through the. corrugating rolls the formed sheet is can riednlong with the corrugatiug heits the lil@ lGS

'.Ward through the machine. The corrugated sheet then passes between the slittcr roll shown at 11 which has fitted -u on its outer surface a plurality of cutting hives 12 in the form of the letter H, such as that shown in Fig. 8. These knives are arranged toV roduce cuts in the sheet such as' that shown 1n Fig. 5 at 13, and alternately positioned along the to of the corrugation as shown he knives contact with lugs 14: on the upper roll 15. After cutting or slit ting in this manner, the sheet proceeds with the endless corrugating belt. y

It will be nqted that the slitting of the corrugation takes place upon the portions between the corrugated bars as the sheet proceeds.

The lower sheet fed from the reel 3 passes over the guide rolls shown at 16, 17 and 18, after which it is immersed in a bath of ad-` hesive material shown at 5 by means of an immersing roll 19 vertically adjustable by means of the handle 20.

After passing through the bath of adhesive material, whch may consist of asphalt or 'bitumen of different character, pitches, sizes or adhesive siliceous substances, or any other type of adhesive material which will fixedly unite and combine the corrugated upper sheet with the lower base sheet.

After passing through the bath, the sheet is directed between doctorblades shown at 21 where the excess adhesive substance is serapedrom the surface of the sheet. The sheet is then fed onto the belt 22 which is fed through a tank or vat 23 containing water or powdered nonadhesivc material which prevents the adhering of the coated sheet v1 to the belt. Under certain conditions water will suffice as a proper non-adhesive medium and under other conditions a pow dered material such as graphite, talc or .other powdered substance proves more satis factory.

The lower sheet 1 and the corrugated sheet 2 are then pressed together between the press rolls 24 and 25, proceeding then with the endless corrugating belt along the supporting table 26 to the punching roll 27 which has positioned thercheneath a roll 28 which supports the sheet during the punching operation.

U on the surface of the punching roll are mem ers 29 which register with the slittcd or cut portions of the corrugation. The function of these punching members 29 is to depress the free ends 13a and 13 shown in Fig. 5 s o that ,they adhere to the lower sheet as shown in Fig. 6. This produces a plurality of depressions designated as 13e in Fig. 6, the adhering of the free ends 13" and 13b to the lower sheet producing a more rigid structure than would be formed by perforations as shown in Fig. 7

These depressed portions not only produce a more rigid construction but also incorporate the advantagesv of the perforations due to the fact that the plastic substance applied to the surface of the corrugated sheet shown in Fig. 6 has much the same ke ing v effect that it would have with the per orations shown in Fig. 7, as the plastic material seeks its way,beneath the side edges of the depression and underneath the raised or corrugated ridges. This is similar to the effect that the plaster substance has with'the apertures shown at 30 in Fig. 7, andthe rigidity as explained, is improved by the fact that the slitted portions 13 and 131J are fixedly united to the lower sheet.

After passing the punching roll the sheet is severed by means of a cutting roll 31 which has on its surface a blade or ,severing knife 32 rotated in a manner to produce the proper length units. Two or more blades may be provided according to the size of the sheet and the rapidity ot" rotation.

In Fig. l at 33 are shown hand wheels which are used to regulate the machine u on the separate sets of rolls positioned .be ow.

The entire structure is mounted upon frame members 34 and the parts are cornbined to operate as asingle unit. lt is essential that the rolls function in timed relation and for this reason an accurate time drive must be furnished.

Power 'from any suitable source, such as a motor shown diagrammatically at 35 drives through the diferential mechanism 36 the sprocket chain 37 which in turn drives the gears 38 and 39, the latter being mounted upon the shaft 40 ositioned longitudinat ly of the machine an having mounted thereon a plurality of bevel gears 4l, 42, 43, 44, 45 and dit. These bevel gears in turn mesh with befvel gears 47, '48, 49, 50, 51 and 52 mounted upon the shafts of the respective units, the details of which are purposely omitted as their relation to the rolls is obvious from Figs. 1 and 2.

ln the modified form of construction in place of slitting the sheet after passing the corrugated roll shown in Fig. 4, the upper sheet is perforated by the perforating meinbers shown at 53 mounted in place ofthe slitting knives on the roll '11. Then the perforating mechanism-is used, a sheet is made such as that shown in Fig. 7 with perforations of an desired configuration,

according to the siape of the pe1"f`orating members upon the ridges or corrugations of the upper sheet.

`When the modified form of construction is employed, it is necessary to remove the punched out disks from the lower roll.

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These disks find their Way from the sheet through the duct el leedingto cylin ricel chaipber 55 in center of the roll lfh Here a screuT conveyor 5G driven from e., sprocket chain 57 troni the upper roll ezipele the disks ns they are punched out. from th center chamber The sheet after cut into units of desired sizes by the cutting roll 3l is ted by means of conveyor belts 58 running from the pulley 59 mounted on the shaft (30 to any desired storage where they are removed :ind bundled or stacked to be shipped.

The sheet produced and the proeessherein explained, has to do with the making oi' plaster board or sheeted lzith to which may be applied plaster, the combination to be used in building construction.

It is understood that e corrugated sheet produced in this manner may be used for innumerable purposes, es hereinbe't'ore suggested.

Heretofore, it has been common gn'eetice to produce corrugated sheeted materiel hy ineens of rolls, but it is thought to he novel to corrugate n sheet in the manner shown, with an endless corrugeting element which marries the corrugated sheet along, and prereuts the stretching" or elongation of the cor rug'etion during subsequent operation of the sheet.

i `further advantage of the sheet is the rigidity produced by the applying;T of e buse materiel coated with an adhesive Substance *which muy be iixedly united or combined 'with the corrugated upper sheet. The edhesive substance utilized in unitirugthe sheets may be of u waterproofing' eher eter Such. :is bituinein pitch or asphalt, or i comprise simply glue or sizing materie as that commercially used at the p time.

The purpose for 'which the ino/teile be used, will determine, the character o adhesive substance best adapted to the to which it is to be put, end also the ch f ter of the sheeted materiel together with i stitiness :ind rigidity. Iihe e factors will necessarily be variables accor ing to the uses to which the product to he put.

claim: Y

l. A process of melting e corrugated board consisting in forming :i sheet into eorrugetions,n making transverseijy'` extend ino; incisions through the sheet at predetermined longitudinal intervals on the crests said eorrugatious, coating second sheet with an adhesive substance, pressing the hase of the corrugetions into Contact with i x igh intervals, eno sQ 't eid corri-gemene? lif with ed hesive substeinze9 uniting the adhesive coated second sheet with the corrugated sheet to form :i unite-ry structure.1

Process off melting e corrugated board 5G' consi stin' i t, n. forming u sheet into corrugetions, j incisions through the Cori-un gated edetermined intervals ai the of seid corrugations, costing second sheet with en hesire substiinee uniting the adhesive coe/red, bese sheet wh the corrugated sheet to i e unitary struetuie, and severing sheets into units.

5. A process of mei: which consists in tori rugations, nml l{Dvi-oups of incisions suitable longitudl l tielly in the eres costing the Y. uniting the ceri o lesite coetedsheet to it, ture, and continuousiy or which the boord is me A procese consisting in Lusing incisions thru the i.ined points in the corregge ond sheet with sn adhesive su uniting the adhesive coated. with `the eorrugeted sheet to tary structure.

7. A process of melting e- I hoard, coi'isistingin oorrugatin' e she ine-king incisions thru the sheet e eorruge" ig e, sheet.- trensiersely e Y:"'hro'ugh the uniting; the edhesii with the corrugzr t structure, pressing the inciseo. portions into the surface the be@ 

